MOBILE DC 12V TO AC 240V 50HZ CONVERTER MOHD NASZRI BIN ZAINAL

Transcription

1 MOBILE DC 12V TO AC 240V 50HZ CONVERTER MOHD NASZRI BIN ZAINAL This report is submitted in partial fulfillment of the requirements for the award of Bachelor of Electronic Engineering (Industrial Electronics) With Honours Faculty of Electronic and Computer Engineering Universiti Teknikal Malaysia Melaka MAY 2008

2 11 UNIVERSITI TEKNIKAL MALAYSIA MELAKA F AKUL 11 KEJURtITERAAN ELEKTRONIK DAN KEJURUTERAAN KOMPUTER BORANGPENG~NSTATUSLAPORAN PROJEK SARJANA MUDA n Tajuk Projek Sesi Peapjiaa MOBlLE OC 12V TO AC 240V 50Hz CONVERTER Saya... MOfID NASZRI BIN ZAINAL.... mengaku membenarkan Laporan Projek Sarjana Muda ini disimpan di Perpustakaan dengan syaratsyarat kegunaan seperti berikut: 1. Laporan adalah hak milik Universiti Teknikal Malaysia Melaka. 2. Perpustakaan dibenark.an membuat salinan untuk tujuan pengajian sahaja. 3. Perpustakaan dibenarkan membuat salinan laporan ini sebagai bahan pertukaran antara institusi pengajian tinggi. 4. Sila tandakan (.J ): D SULIT- (Mengandungi maklumat yang berdarjah keselamatan atau kepentingan Malaysia seperti yang termaktub di dalam AKT A RAHSlA RASMI 1972) D TERHAD* [Z] TIDAK TERHAD (Mengandungi maklumat terbad yang telah ditentukan oleh organisasilbadan di mana penyelidikan dijalankan) Disahkan oleh: (TANDAT9 PENULIS) A1arnat Tetap: BA TV 4 \12 KG KANDANG, 75460, MELAKA. ".5.0, Tarikh: ,.. SITI KHADIJAH OTHMAN Pensyarah Fakulti Kej Elektronik dan I(ej Kumpu!er IF KEKK) Universiti Teknikal Malavsia Melaka IU TeM), Karung Berkunci 1}I1U. Ayer Keroh Melaka. Tarikh: i./.~jtJ.. r....

3 III "I hereby declare that this report is the result of my own work except for quotes as cited in the references." Signature Author Date :... ~.... :Mohd Naszri Bin Zaina) q.5 0f;

4 IV "I hereby declare that 1 have read this report and my opinion this report is sufficient in tenos of the scope and quality for the award of Bachelor of Electronic Engineering (Industrial Electronics) With Honours." Signature Supervisor's Name Date :~.. ~;~~~ :... ~.f '(J.l....

5 v This project is dedicated to my mother Mrs.Saleha Bte Baba From all her support, I have been finished this thesis. I will never forget whatever kind of help that comes from her in completing this project. Not forget also to all my family members especially my brother Mohd Naszrul B Zainal and my entire relative. Next is to all of my friends especially my housemate. Last but not least to my supervisor Mrs. Siti Khadijah Bte Idris@Othman.

6 vi ACKNOWLEDGEMENT First of all, I would like to thank Allah the All Mighty, which with his bless, I manage to complete this thesis. I would like to express my greatest gratitude and sincere thanks to my supervisor, Mrs. Siti Khadijah Bte Idris@Othman, for accepting me as her project student and for her valuable ideas, advice and help in the supervision and discussions of this Final Year Project. In fact, she gave me guidance when obstacles arise throughout this period of time. Once again, I thank her for her tolerance and endeavors. Last but not least, I would like to express gratitude to my entire friend especially to all my housemate. They are Mohd Seth Bin Sulaiman, Mohd Farid 8 Sudin, Mohd Haidy 8 Dzulfakry Thani, Azzad Firdaus 8 Zolkepli, Khairil Aizat B Mohamed and Syed Syahmi Wafa B Syed Sulaiman. With all of they help, I have been successfully complete this project. Without their help, I think this project cannot be finished only by me.

7 vii ABSTARCT This project title is mobile DC 12V to AC 240V 50Hz converter which is a device that will convert a DC voltage to AC voltage. When we traveling in car, there is some problem that might be occurring such as our handset battery flat and we need it for emergency cases. This project might help a little bit to overcome this problem. User can get an AC supply in their car just connect this converter to the cigarette lighter slot and then it will produce an AC voltage. This converter is design small so it can be mobile and save space in the vehicle. This converter is suitable to use for charging handset and laptop.

8 viii ABSTRAK Tajuk untuk projek ini adalah pengubah 12V DC kepada 240V AC 50 Hz mudah alih. Apabila kita melakukan perjalanan menaiki kenderaan contohnya kereta, kita akan menghadapi sesetengah masalah seperti telefon kehabisan bateri dan kita amat memerlukannya untuk membuat panggilan contohnya ketika kecemasan. Melalui projek ini sedikit sebanyak dapat menyelesaikan masalah tersebut. Pengguna boleh mendapatkan bekalan elektrik 240V AC dengan hanya menyambungkan pengubah ini kepada slot penghidup api di dalam kereta dan ia akan menghasilkan bekalan elektrik. Penukar ini direka agar tidak terlalu besar agar mudah dibawa kemana sahaja dan menjimatkan ruang ketika digunakan di dalam kereta. Pengubah ini paling sesuai untuk digunakan untuk cas semula bateri telefon dan komputer riba.

9 ix CONTENTS CHAPTER TITLE PAGE PROJECT TOPIC VERIFICATION FORM DECLARATION VERIFICATION DEDICATION ACKNOWLEDGEMENT ABSTRACT ABSTRAK CONTENTS LIST OF TABLES LIST OF FIGURES LIST OF APPENDIX ii iii iv v vi vii viii ix xii xiii xvi I INTRODUCTION Project background Objective of project Scope of project Problem statement Method of project 3

10 x n LITERATURE REVIEW Historic of inverter Early lnverter Controlled Rectifier Inverters Rectifier and Inverter Pulse numbers Inverter Application DC Power Source Utilization Un interruptible Power Supply Induction Heating HVDC Power Transmission Variable-Frequency Drive Electric Vehicle Drives Inverter Circuit Description Basic Inverter Designs Inverter Output Waveforms More Advance Inverter Design Three Phase Inverter 14 m METHODOLOGY PROJECT Block Diagram Block I(Input) Battery 12V Relay Led Indicator Zener Diode Block 2(NE555 Oscillator) Block 3(Amplifier) Block 4(Transfonner Step Up)

11 xi Block 5(Output 240V) 3.2 Converter Circuit 3.3 List of Component 3.4 PCB Development 3.4 Flow Chart IV RESUL T AND ANALYSIS 4.1 Overview 4.2 Converter 4.3 Troubleshooting 4.4 Final Product V CONCLUSION AND SUGGESTION 5.1 Conclusion 5.2 Suggestion REFERENCES 57 APPENDIX 66

12 xii LIST OF TABLES NO TOPICS PAGES 3.1 List of Component 39

13 xiii LIST OF FIGURE FIGURE TITLE PAGE Figure 1.1 Block diagram 3 Figure pulse line-commutated inverter circuit 6 Figure V DC to 240V AC inverter 8 Figure 2.3 Un interruptible power supply 8 Figure 2.4 Sell Solid-State High Frequency Induction Heating 9 Power Supply Figure 2.5 Variable-frequency drive 10 Figure 2.6 Simple inverter with an electromechanical switch 11 and with a transistor switch Figure 2.7 H-bridge inverter circuit with transistor switches 14 and anti parallel diodes Figure phase inverter with wye connected load 15 Figure phase inverter switching circuit showing 15 6-step switching sequence and waveform of voltage between terminals A and C Figure 3.1 Block diagram 17 Figure 3.2 Car Battery 18 Figure 3.3 Cigarette lighter slot 19 Figure 3.4 Relay Diagram 20 Figure 3.5 SPDT Relay 20 Figure 3.6 Red LED 21

14 xiv Figure 3.7 LED schematic 21 Figure 3.8 Zener diode 22 Figure 3.9 NE Figure 3.l0 Pin connection 23 Figure 3.11 NE555 block diagram 24 Figure 3.12 NE555 schematic diagram 25 Figure 3.13 Oscillator circuit 25 Figure 3.14 Output ofne Figure 3.15 Connection Diagram 26 Figure 3.16 Class A amplifier 28 Figure 3.17 Class B amplifier 29 Figure 3.18 Class C amplifier 29 Figure 3.19 Replica of first transistor 31 Figure 3.20 BJT diagram 33 Figure 3.21 Transformer 34 Figure 3.22 An ideal step-down transformer showing 36 magnetic flux in the core Figure 3.23 Winding in transformer 36 Figure 3.24 Output socket 37 Figure 3.25 Laptop charger 37 Figure 3.26 Schematic diagram 38 Figure 3.27 PCB layout for converter circuit 41 Figure 3.28 Transparency layout for converter circuit 41 Figure 3.29 UV machine 42 Figure 3.30 Etching machine 42 Figure 3.31 PCB for converter circuit 43 Figure 3.30 Etching machine 42 Figure 3.31 PCB for converter circuit 43 Figure 4.1 Block Diagram 45 Figure 4.2 Converter Schematic Diagram 47 Figure 4.3 Output ofne555 47

15 xv Figure 4.4 Converter Circuit 48 Figure 4.5 First circuit 49 Figure 4.6 New circuit 49 Figure 4.8 Frequency 51 Figure IC output 52 Figure 4.10 Amplifier output 53 Figure 4.] ] Casing 51 Figure 4.]2 Final Product 55 Figure 4.13 Final Product 55

16 xvi LIST OF APPENDIX NO TITLE PAGE A B C NE555 Data Sheet SDI047 Data Sheet Relay Data Sheet

17 CHAPTER I INTRODUCTION 1.1 Project Background This project title is mobile DC 12V to AC 240V 50Hz converter which is a device that will convert a DC voltage to AC voltage. The main idea of this project is we will able to get 240V source in motor vehicle like car, mpv and many more even when we are getting outdoor activities such as camping where we just need to bring a 12V battery. The output 240V AC can be used to recharge the laptop, PDA and many lower current rate device by using the normal available charger provide by gadget manufacture. The word mobile means this device is movable which it is not huge in size where it can be placed anywhere and did not use large area when put in vehicle. This invention will avoid headache to find out the compatible in car charger for each gadget you have. The significant we can get from this project is this project is a useful kit to apply in any vehicle. This project also will make user save their money from buy many charger to use in vehicle because for each device there were different chargers. This converter is not only for using in vehicle but it also can be apply when doing outdoor activities such as camping when we need an ac source and we just need to bring a 12V battery. This project can be developing to a high watt converter for high watt device such as TV and microwave.

18 2 1.2 Objective Of Project The objective of this project is to design a converter circuit that produce 240V AC output from 12V DC input. The input is come from 12V battery. When we apply this converter in vehicle we can plug in the input in the cigarette lighter slot and when for outdoor usage there is cable to connect the input to the battery. The next objective is to understand the concept of this converter. All the process from beginning or input from DC to AC output must be understandable. How this converter work and how it convert from DC to AC also must be know. Last but not least to make this converter mobile and easy to apply. The word mobile means this converter is small in size where it will use less space while using it in vehicle and light. This converter is simple to apply where it just need to connect to the input and it ready to use. 1.3 Scope of Project This project only uses an electronic component that will convert DC 12V to AC 240V. It will use 555 IC to convert the DC to AC and step up it using transformer. In the middle of the process of step up and convert there will be amplifying process which use an amplifier circuit to make the AC is suitable to step up. The power usage from this converter is only below 10Owatt. The devices that can use this converter are low watt device such as charger for handset, PDA, laptop, i-pod and many more. When the device that been use is more than l00watt, this converter will overload and the fuse will be automatic burn. It will maintain the same frequency as main power source which is 50Hz. This project must be design not to big so it will save space while using it in vehicle and it also mobility where it can be take anywhere. It is also light and small so it easy to bring anywhere.

19 3 1.4 Problem Statement When traveling in vehicle. we have some difficulty such as to charge our handset, laptop. PDA and many more low current devices. It will make difficulties to us when we need that device for some emergency cases such as handset but it cannot use because out of battery when we traveling. Each device have different charger for in vehicle usage. It will cost a lot of money to buy many different chargers. This project will help out user a little bit where they can save their money. 1.5 Method of Project Input 12V Battery IC555 Amplifier Transformer Output f-+ Oscillator r+ -+ Step Up r+ 240V Figure 1.1: Block diagram

20 CHAPTERll LITERATURE REVIEW 2.1 Historic Of Inverter Early Inverter From the late nineteenth century through the middle of the twentieth century, DC-to-AC power conversion was accomplished using rotary inverters or motorgenerator sets. In the early twentieth century, vacuum tubes and gas filled tubes began to be used as switches in inverter circuits. The most widely used type of tube was the thyratron. The origins of electromechanical inverters explain the source of the term inverter. Early AC-to-DC inverters used an induction or synchronous AC motor direct-connected to a generator (dynamo) so that the generator's commutator reversed its connections at exactly the right moments to produce DC. A later development is the synchronous inverter, in which the motor and generator windings are combined into one armature, with slip rings at one end and a commutator at the other and only one field frame. The result with either is AC-in, DC-out. With an M-G set, the DC can be considered to be separately generated from the AC; with a synchronous inverter, in a certain sense it can be considered to be "mechanically rectified AC". Given the right

21 5 auxiliary and control equipment, an M-G set or rotary inverter can be llrun backwards ll, converting DC to AC Controlled Rectifier Inverters Since early transistors were not available with sufficient voltage and current ratings for most inverter applications, it was the 1957 introduction of the thyristor or silicon-controlled rectifier (SCR) that initiated the transition to solid state inverter circuits. The commutation requirements of SCRs are a key consideration in SCR circuit designs. SCRs do not turn off or commutate automatically when the gate control signal is shut off. They only turn off when the forward current is reduced to zero through some external process. For SCRs connected to an AC power source, commutation occurs naturally every time the polarity of the source voltage reverses. SCRs connected to a DC power source usually require a means of forced commutation that forces the current to zero when commutation is required. The least complicated SCR circuits employ natural commutation rather than forced commutation. With the addition of forced commutation circuits, SCRs have been used in the types of inverter circuits described above. In applications where inverters transfer power from a DC power source to an AC power source, it is possible to use AC-to-DC controlled rectifier circuits operating in the inversion mode. In the inversion mode, a controlled rectifier circuit operates as a line commutated inverter. This type of operation can be used in HYDC power transmission systems and in regenerative braking operation of motor control systems. Another type of SCR inverter circuit is the current source input (CSn inverter. A CSI inverter is the dual of a six-step voltage source inverter. With a current source inverter, the DC power supply is configured as a current source rather than a voltage source. The inverter SCRs is switched in a six-step sequence to direct the current to a three-phase AC load as a stepped current waveform. CSI inverter

22 6 commutation methods include load commutation and parallel capacitor commutation. With both methods, the input current regulation assists the commutation. With load commutation, the load is a synchronous motor operated at a leading power factor. As they have become available in higher voltage and current ratings, semiconductors such as transistors that can be turned off by means of control signals have become the preferred switching components for use in inverter circuits. + series-conneded transformer serondary wind' E Figure 2.1: 12-pulse line-commutated inverter circuit Rectifier And Inverter Pulse Numbers Rectifier circuits are often classified by the number of current pulses that flow to the DC side of the rectifier per cycle of AC input voltage. A single-phase half-wave rectifier is a one-pulse circuit and a single-phase full-wave rectifier is a two-pulse circuit. A three-phase half-wave rectifier is a three-pulse circuit and a three-phase full-wave rectifier is a six-pulse circuit. With three-phase rectifiers, two or more rectifiers are sometimes connected in series or parallel to obtain higher voltage or current ratings. The rectifier inputs are supplied from special transformers that provide phase shifted outputs. This has the effect of phase multiplication. Six phases are obtained from two transformers, twelve

23 7 phases from three transformers and so on. The associated rectifier circuits are 12- pulse rectifiers, 18-pulse rectifiers and so on. When controlled rectifier circuits are operated in the inversion mode, they would be classified by pulse number also. Rectifier circuits that have a higher pulse number have reduced harmonic content in the AC input current and reduced ripple in the DC output voltage. In the inversion mode, circuits that have a higher pulse number have lower harmonic content in the AC output voltage waveform. 2.2 Inverter App6cations There are many devices that use inverter application. For example DC power source utilization, uninterruptible power supplies, induction heating, high-voltage direct current (HVDC) power transmission, variable-frequency drives and electric vehicle drives DC Power Source Utilization An inverter allows the 12 or 24 volt (battery) DC power available in an automobile or from solar panels to supply AC power to operate equipment that is normally supplied from a main power source. Inverters are also used to provide a source of AC power from photovoltaic solar cells and fuel cell power supplies.

24 8 Figure 2.2: 12V DC to 240V AC inverter Uninterruptible Power Supplies One type of uninterruptible power supply uses batteries to store power and an inverter to supply AC power from the batteries when main power is not available. When main power is restored. a rectifier is used to supply DC power to recharge the batteries. Figure 2.3: Uninterruptible power supply